Machine Tool Casting Manufacturer

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Process flow for customizing machine tool castings

Customization of machine tool castings requires a series of rigorous processes to ensure that the product meets design requirements and performance. The specific process flow is as follows:

1、 Requirement analysis and drawing design

Firstly, communicate deeply with the customer to clarify the purpose, performance requirements, size specifications, material preferences, and batch size of the castings. Based on these requirements, engineers use professional design software such as CAD and UG to design drawings, marking key dimensional tolerances, surface roughness, mechanical properties, and other parameters. Simultaneously conducting simulation analysis, predicting the stress and deformation of castings during use, optimizing structural design, and avoiding problems in the later stage.

2、 Mold making

Produce casting molds based on design drawings, commonly used mold materials include cast iron, steel, etc. The accuracy of the mold directly affects the accuracy of the casting, so it is necessary to strictly follow the drawings for processing to ensure that the dimensional tolerances and surface roughness of the mold meet the requirements. For complex castings, split mold production can be used, followed by assembly and debugging to ensure accurate mold fit and avoid defects such as burrs and misalignment.

3、 Material selection and melting

Select suitable cast iron materials based on the performance requirements of the castings, such as gray cast iron, ductile iron, etc. Pour the selected raw materials into the furnace in proportion for melting, control the melting temperature and time, and ensure that the composition of the molten metal is uniform and pure. At the same time, conduct pre furnace testing to detect the chemical composition of the metal liquid, such as the content of elements such as carbon, silicon, manganese, etc., to ensure compliance with material standards.

4、 Casting and Forming

Pour the melted and qualified metal liquid into the made mold, and use appropriate casting processes such as sand casting, lost foam casting, etc. During the casting process, control parameters such as casting speed and temperature to avoid casting defects such as insufficient casting, porosity, and shrinkage. After the metal liquid cools and solidifies, demold and remove the casting blank.

5、 Sand cleaning and polishing

Clean the casting blank to remove surface sand, sprues, etc. Then polish and trim the burrs and edges of the casting to make the surface smoother and more even, preparing for subsequent processing.

6、 Heat treatment

According to the material and performance requirements of the castings, corresponding heat treatment processes are carried out, such as annealing, normalizing, quenching, etc. Heat treatment can improve the internal structure of castings, enhance their mechanical properties such as strength, hardness, and wear resistance, eliminate casting stress, and reduce deformation during subsequent processing and use.

7、 Mechanical processing

Perform mechanical processing such as turning, milling, and grinding on castings according to the drawing requirements, accurately controlling the dimensional accuracy and surface roughness of the castings. During the machining process, high-precision machining equipment and tools are used, and regular calibration and maintenance are carried out to ensure stable machining quality. Simultaneously conducting intermediate inspections to promptly identify and resolve any issues that arise during the processing.

8、 Quality inspection

Conduct comprehensive quality inspection on the processed castings, including dimensional accuracy testing (using coordinate measuring instruments and other equipment), surface quality testing (such as roughness meter testing), mechanical performance testing (such as hardness testing, tensile testing, etc.), and internal quality testing (such as ultrasonic testing, radiographic testing, etc.). Ensure that all indicators of the castings meet the design requirements and relevant standards.

9、 Surface treatment

Surface treatment of castings according to customer requirements, such as painting, galvanizing, phosphating, etc. Surface treatment can improve the corrosion resistance, aesthetics, and wear resistance of castings, and extend their service life.

10、 Packaging and Shipping

After cleaning and drying qualified castings, appropriate packaging methods should be used to prevent damage during transportation. Then arrange shipment according to customer requirements to ensure the safety and timely delivery of castings to customers.